Prague 2004
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Transcript of Prague 2004
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Prague 2004
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Plant Data Kilns 2 x 1,300 tpd clinker
Vertical Coal Mill 15 tph
Cement Mills 3 x 100 tph + 1 x 30 tph
Own Quarries for Marl, Limestone and Sand
Reserves of Raw Materials: Approximately 30 Years for marl and limestone
Insulation Material Production Plant
RMC Plant
Number of Employees: 574
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Location of “USJE”
• Located in the southeastern part of Skopje
• 3.5 km. from the center of the town
• Surrounded by civilian houses
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The location of the factory brings up the:
ENVIRONMENTALENVIRONMENTAL QUESTIONQUESTION
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The manufacturing of the cement influences the environment
• Excavation of the raw materials changes the landscape• Transportation of the raw materials as a source of dust• The production of clinker has the biggest impact on
the environment– Big usage of energy– Air emissions ( dust, SO2, NOx, CO…)
• Storage of clinker, grinding of clinker and packing of cement are also dust sources
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The environmental impact of the working processes of “USJE” has been
mitigated through the technicaltechnical and technologicaltechnological
interventions
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These improvements are accomplishedaccomplished through the years
• 1993 – Two concrete silos for clinker (25000 tones each) with a closed belt
conveyer and a complete dedusting system
• 1993 – Electrostatic precipitator for clinker cooler (each kiln has it)
• 1997 – Gasification of the boiler room for production of steam
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• 1999 – Bag filters for cement mills 4, 5 & 6
• 1999 – Bag filter for rotary Kiln No. 3
• 2001 – Vertical mill for petcoke, with bag filter and system for fire protection
• 2003 – Bag filter for rotary Kiln No. 4
• 2004 – Puzzolana substituted by Fly Ash
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Continuous Emissions Monitoring
• Installation of a network which connects all measuring instruments– Instruments for dust measurement installed on:
• Coal Mills• Cement Mills• Raw Mill Preparation• Exhaust Gases
– Instruments for measurement of SO2, NOx, and flow installed on:
• Stack
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• August 2004 – integration of all “in – situ” signals in the network (company “SICK” has installed the software program
“MEAC 2000”)
• ON – LINE regular reporting on a 30 min basis
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Trial use of shredded tyres as an alternative fuel in rotary Kiln No. 4
Phase 1:Phase 1: Getting necessary permissions
Phase 2:Phase 2: ACTION PLAN – Internal preparation of the plant
Phase 3:Phase 3: Experimental testing:
15th – 17th September 2004
Phase 4:Phase 4: Results from the testing
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Environmental Legislation
• Current Law in force– Limit values:
• SO2 = 400 mg/Nm3 ( mean 67,9-USJE )
• NOx = 1300 mg/Nm3 (mean 834,6-USJE)
• Dust = 50 mg/Nm3 (mean 15,8-USJE)
• Proposed version that is in Parliamentary procedure adjusted to the EU Law
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To comply with BAT
• Raw materials handling and storage– Pre-blending system– Excess clinker storage
• Fuel preparation– Bag filter for the horizontal coal mill
• Process– Process optimisation
– NOx reduction
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To comply with BAT
• Process (cont.)– Electricity use optimisation– ESP reconstruction or bag filters for cement
mills– Bag filters for clinker coolers– Noise reduction
• EMS establishing– ISO 14000
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Cost/Benefit Analysis for BAT compliance
• Estimated total Investment costs 6.100.000 (consultants estimation)
• Estimated Difference in Operation Costs - 475.000 year (consultants estimation)
(Only SNCR increases operation costs)
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Conclusion
1. Applying BAT will have an impact on the competitiveness of the company due to a long pay-back period
2. The impact can be minimised by allowing a reasonable number of years for successive investment